Collar for a wall anchor

ABSTRACT

A wall anchor for use in a cavity wall that connects to a veneer tie to join an inner wythe and an outer wythe of the cavity wall includes an elongate body and a collar. The elongate body has a driven end and a driving end and defines a longitudinal axis extending between the driven and driving ends. The collar connects to the veneer tie. The collar includes a body mounting portion mounted on the elongate body. The body mounting portion defines an aperture through which the elongate body extends and includes a first aperture forming portion and a second aperture forming portion. The first and second aperture forming portions define at least a portion of the aperture through which the elongate body extends. The first and second aperture forming portions are longitudinally offset with respect to one another along the longitudinal axis of the elongate body.

FIELD OF THE INVENTION

The present disclosure generally relates to a facade support system used in building construction, and more specifically, a collar for a wall anchor that connects to a veneer tie.

BACKGROUND OF THE INVENTION

A facade can be a durable and aesthetically desirable construction for a building exterior. Facades, such as brick or stone veneer walls, also provide protection to the interior of the building from the surrounding environment and are typically used in cavity wall structures. Anchoring systems are used to secure facades (e.g., an outer wythe of the cavity wall) to inner walls (e.g., an inner wythe of the cavity wall) of a building to overcome forces which might pull the facade away from the building. The anchoring systems generally include a wall anchor for insertion into an inner wythe of the cavity wall and a veneer tie that is embedded in a mortar joint of the outer wythe or brick veneer and connected to the wall anchor.

SUMMARY OF THE INVENTION

In one aspect, a wall anchor for use in a cavity wall that connects to a veneer tie to join an inner wythe and an outer wythe of the cavity wall generally comprises an elongate body having a driven end and a driving end. The elongate body defines a longitudinal axis extending from the driven end to the driving end. The driven end is configured to connect to the inner wythe of the cavity wall. A collar is configured to connect to the veneer tie. The collar includes a body mounting portion mounted on the elongate body adjacent to the driving end. The body mounting portion defines an aperture through which the elongate body extends. The body mounting portion includes a first aperture forming portion and a second aperture forming portion. The first and second aperture forming portions define at least a portion of the aperture through which the elongate body extends. The first and second aperture forming portions are longitudinally offset with respect to one another along the longitudinal axis of the elongate body.

In another aspect, a method of making a collar that connects a veneer tie to an elongate body of a wall anchor is described. A collar blank is cut from a sheet of material. A remainder of the collar blank is deformed outwardly in a first direction to form a first aperture forming portion. The reminder of the collar blank is deformed outwardly in a second direction opposite the first direction to form a second aperture forming portion at a location on the collar blank so that, as deformed from the collar blank, the first and second aperture forming portions are aligned to define an aperture having a central axis. The first and second aperture forming portions are offset from each other along the central axis. The aperture is sized and shaped to receive the elongate body therethrough along the central axis for mounting the collar on the elongate body. A structure is formed on the collar blank that is configured to connect the veneer tie to the collar.

Other objects and features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of an anchoring system connecting an inner wythe of a cavity wall and an outer wythe of the cavity wall;

FIG. 2 is a fragmentary sectional view looking down from above on the anchoring system of FIG. 1 in use;

FIG. 3 is a perspective of a wall anchor of the anchoring system including a collar according to one embodiment of the present disclosure;

FIG. 4 is a rear perspective of the collar;

FIG. 5 is a front view thereof.

FIG. 6 is a rear view thereof;

FIG. 7 is a top view thereof;

FIG. 8 is a bottom view thereof;

FIG. 9 is a right side view thereof; and

FIG. 10 is a left side view thereof.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 and 2, one embodiment of a collar according to the teachings of the present disclosure for use in an anchoring system 32 for a cavity wall 12 is generally indicated at 10. The cavity wall 12 is shown having an inner wythe 14 and an outer wythe 20 with a cavity 22 formed there-between separating the inner and outer wythes. In the illustrated embodiment, the inner wythe 14 is of stud frame construction and includes with sheetrock or wallboard 16 mounted on metal studs or columns 18 with an air/vapor barrier 24 and insulation 26 mounted on the wallboard. The inner wythe 14 may also be of concrete or masonry construction (not shown). The outer wythe or facade 20 is of brick construction. The inner and outer wythes may have other constructions than described herein that are within the scope of the present disclosure.

The outer wythe 20 has successive bed joints 30 filled with mortar formed between courses of bricks 28 and are substantially planar and horizontally disposed. In accordance with building standards, the bed joints 30 are approximately 0.375 inches (0.95 cm) in height in a typical embodiment. Selective bed joints 30 receive a veneer tie 34 which extends from the bed joint across the cavity 22 to a wall anchor 36 mounted on the inner wythe 14 to connect the outer wythe 20 to the inner wythe. The wall anchor 36, as described in greater detail below, is threadably mounted on the inner wythe 14 and is supported by the inner wythe.

For purposes of illustration, the exterior surface of the air/vapor barrier 24 of the inner wythe 14 contains a horizontal line or x-axis 38 and intersecting vertical line or y-axis 40. A horizontal line or z-axis 42, normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes.

In the illustrated embodiment, the anchoring system 32 includes the wall anchor 36, the veneer tie 34, and a wire or outer wythe reinforcement 44. At intervals along the exterior surface of the inner wythe 14, wall anchors 36 are driven into place. Holes in the inner wythe 14 that receive the wall anchor 36 can be pre-drilled, or, alternatively, the wall anchor 36 can be self-tapping. The wall anchors 36 are positioned on surface 24 so that a longitudinal axis LA of the wall anchor 36 is normal to the xy-plane and taps into stud 18. Each veneer tie 34 is emplaced on a course of bricks in preparation for embedment in the mortar of bed joint 30. The veneer tie 34 is formed of wire and includes pintles 50 that connect to the wall anchor 36, as is known in the art. The wire reinforcement 44 is also constructed of a wire, as is known in the art.

Referring to FIG. 3, the wall anchor 36 includes an elongate body or bolt 40 and the collar 10 mounted on the elongate body. The wall anchor 36 may also include a washer 42 mounted on the bolt 40 and configured to engage the exterior surface of the inner wythe 14. The washer 42 may be any suitable washer such as, but not limited to, a neoprene washer. The elongate body 40 has a driven end 44 and a driving end 46. The bolt 40 defines the longitudinal axis LA of the wall anchor 36, the longitudinal axis extending from the driven end 44 to the driving end 46. The bolt 40 includes a drive head 48 disposed at the driving end 46 configured to be driven to secure the elongate body to the inner wythe 14. As illustrated, the drive head 48 is a bolt head, such as a hex head, capable of being driven using a tool, such as a wrench or a power driver. The bolt 40 includes a self-tapping tip 52 disposed at the driven end 44 configured to enable the bolt to be threaded into the inner wythe 14 without the pre-drilling of a hole. The bolt 40 includes a center portion 54 extending between the self-tapping tip 52 and drive head 48. The center portion 54 has a circular cross-sectional shape with a diameter. The center portion 54 of the bolt 40 includes external threads so that the elongate body can be screwed into the stud 18 of the inner wythe 14. The threads extend from the self-tapping tip 52 toward the drive head 58 along the center portion 54. Preferably, the threads extend along the entire center portion 54 from the self-tapping tip 52 to the drive head 58. In use, the driven end 44 is driven into stud 18, mounting the wall anchor 36 on the inner wythe 14. The bolt 40 can be of any suitable length. Other configurations of the elongate body are within the scope of the present disclosure.

Referring to FIGS. 3-10, the collar 10 is configured to be mounted on the bolt 40 and to connect to the veneer tie 34, thereby connecting the veneer tie to the wall anchor 36. The collar 10 includes a bolt mounting portion 60 (broadly, a body mounting portion) configured to be mounted onto the bolt 40. The bolt mounting portion 60 defines an aperture 62 configured to receive the bolt 40. The bolt 40 extends through the aperture 62 of the collar 10 when the collar is mounted to the elongate body. In addition, when mounted on the bolt 40, the bolt mounting portion 60 is near (e.g., adjacent) the driving end 46. Preferably, the collar 10 touches the drive head 48 when mounted to the elongate body 40. The aperture 62 defines a central axis CA that extends through the aperture. When attached to the elongate body 40, the central axis CA of the collar 10 and longitudinal axis LA of the elongate body are generally coextensive. Preferably, the aperture 62 has a diameter that is larger than the diameter of the elongate body 40 so that both the collar 10 and elongate body are free to rotate with respect to each other about the longitudinal axis LA (e.g., central axis CA) when the collar is mounted on the elongate body. It is understood the collar 10 can be use or mounted on any suitable elongate body, including an elongate body having a different construction than described herein.

The collar 10 includes two wings 64 (broadly, at least one wing) connected to the bolt mounting portion 60. Each wing 64 is configured to connect to the veneer tie 34. Each wing 64 defines a connecting aperture 66 for receiving the veneer tie 34, specifically, for receiving one of the pintles 50 of the veneer tie. The collar may have any number of wings, but generally one or two is most practical. As shown in FIGS. 1 and 2, the pintles 50 of the veneer tie 34 are inserted into the connecting aperture 66 of each wing 64 to secure the veneer tie to the collar 10 and, thereby, the wall anchor 36. Each wing 64 extends outward from the bolt mounting portion 60 in a direction that is generally away or outward from (e.g., perpendicular to) the central axis CA (e.g., longitudinal axis LA).

Still referring to FIGS. 4-10, the bolt mounting portion 60 includes two or more aperture forming portions, each aperture forming portion forming or defining at least a portion of the aperture 62 the elongate body 40 extends through. In the illustrated embodiment, the bolt mounting portion 60 includes three aperture forming portions 68 a, 68 b and 68 c, respectively. In other embodiments, the bolt mounting portion 60 may have less or more aperture forming portions such as, but not limited to, two, four, five, six or more aperture forming portions. Each aperture forming portion 68 a, 68 b, 68 c is longitudinally offset with respect to at least one other aperture forming portion along (e.g., in the direction defined by) the longitudinal axis LA (e.g., central axis CA). For reasons that will become apparent, preferably, each aperture forming portion 68 a, 68 b, 68 c is longitudinally offset with respect to every other aperture forming portion along the longitudinal axis LA. In other words, in the preferred embodiment, none of the aperture forming portions 68 a, 68 b, 68 c overlap with one another (e.g., an imaginary line transverse to and extending through the central axis CA at any position on the central axis only contacts one aperture forming portion). In the illustrated embodiment, each aperture forming portion 68 a, 68 b, 68 c defines approximately one half or one side of the aperture 62. In addition, more than one aperture forming portion 68 a, 68 b, 68 c can be used to define one side of the aperture 62. For example, in the illustrated embodiment, aperture forming portions 68 a and 68 c define one side of the aperture 62 and aperture forming portion 68 b defines the other side of the aperture. In other embodiments, more than two aperture forming portions may be used to define one side of the aperture 62 such as, but not limited to, three, four or more aperture forming portions. Each aperture forming portion 68 a, 68 b, 68 c is an arcuate strip that extends from the interior (i.e., closest to the central axis CA) edge margin of one wing 64 to the interior edge margin of the other wing. Each strip of each aperture forming portion 68 a, 68 b, 68 c extends generally transversely to the central axis CA.

The bolt mounting portion 60 includes at least one aperture forming portion 68 a, 68 b, 68 c disposed on one side of the central axis CA and at least one aperture forming portion disposed on the other side of the central axis. In this manner, at least two of the aperture forming portions 68 a, 68 b, 68 c disposed on opposite sides of the central axis CA fully define and circumferentially enclose the aperture 62. In the illustrated embodiment, the aperture forming portions 68 a and 68 c are disposed on one side of the central axis CA and aperture forming portion 68 b is disposed on the other side of the central axis. For example, as shown in FIG. 9, aperture forming portions 68 a, 68 c are disposed on the left side the central axis CA and aperture forming portion 68 b is disposed on the right side the central axis CA. Aperture forming portion 68 b is disposed between aperture forming portions 68 a, 68 c such that the side of the central axis CA on which each aperture forming portion is disposed alternates along the central axis. However, it will be understood that aperture forming portions need not alternate so long as there remains one or more aperture forming portions on opposite sides of the central axis CA.

Aperture forming portion 68 a is proximally disposed on the collar 10 with aperture forming portion 68 b disposed distal of aperture forming portion 68 a and aperture forming portion 68 c disposed distal of aperture forming portion 68 b. In the illustrated embodiment, each aperture forming portion 68 a, 68 b, 68 c is longitudinally offset and spaced apart from every other aperture forming portion along the central axis CA. As shown in FIG. 5, aperture forming portions 68 a and 68 b are longitudinally spaced apart from one another such that they define a longitudinal gap 70 there-between. Similarly, aperture forming portions 68 b and 68 c are longitudinally spaced apart from one another such that they define a longitudinal gap 70 there-between. In other embodiments, adjacent aperture forming portions may not be spaced apart. Moreover, because each aperture forming portion 68 a, 68 b, 68 c is longitudinally offset and spaced apart from one another, aperture forming portions on the same side of the central axis CA define a gap 72 there-between as well (FIG. 8) which is opposite the aperture forming portion 68 b on the other side of the central axis CA. In other words, each aperture forming portion 68 a, 68 b, 68 c has a corresponding gap 72 (e.g., open space) on the opposite side of the central axis CA in the bolt mounting portion 60. In one embodiment, the interior surface (e.g., the surface facing the central axis CA) of each aperture forming portion 68 a, 68 b, 68 c is threaded. Accordingly, in this embodiment, the collar is screwed onto the bolt 40.

In the illustrated embodiment, the distal most aperture forming portion 68 c and the wings 64 define a drive head receiving space 74 configured to receive the drive head 58 of the elongate body 40 when the elongate body is inserted through the aperture 62.

In one embodiment, the collar 10 is formed as one piece of material. For example, the collar 10 can made from a single piece of material by stamping. In this embodiment, a metal blank is cut from a piece of material such as a sheet metal roll. In one embodiment, the metal blank is stamped from 12 gauge steel, although other thicknesses (e.g., 9-20 gauge) and other suitable materials (e.g., aluminum) are within the scope of the present disclosure. After the metal blank is cut, the metal blank is deformed, by stamping, to form the bolt mounting portion 60. Specifically, a portion of the metal blank is pushed in a first direction to form one aperture forming portion 68 a, 68 b, 68 c and a portion of the metal blank is pushed in a second direction to form another aperture forming portion. The first and second directions are generally opposite to one another. In addition, the first and second directions are generally transverse to the central axis CA. When there is more than one aperture forming portion 68 a, 68 b, 68 c defining one side of the aperture 62, such as aperture forming portions 68 a and 68 c in the illustrated embodiment, each portion of the metal blank corresponding to the aperture forming portions defining one side of the aperture are pushed (e.g., deformed) in the same first or second direction at the same time. Pushing the portion or portions of the metal blank in the second direction may occur after pushing the portion or portions of the metal blank in the first direction or pushing in the second direction may occur simultaneously with pushing in the first direction. Other ways of forming the collar 10, including different sequences of stamping and forming, are within the scope of the present disclosure. Moreover, in one embodiment the bolt mounting portion 60 and wings 64 are separate components that are welded together.

The configuration of the collar 10, as described herein, enables the collar to be cut from a single piece of material and bent into shape (e.g., stamping), without folding a portion of the metal blank back on itself or joining two plates together, as previously done in the art. Specifically, because the aperture forming portions 68 a, 68 b, 68 c are longitudinally offset from one another, different aperture forming portions can be pushed (e.g., bent, deformed) in different directions during the stamping process to form the aperture 62. This is not possible with the configuration of existing collars which require folding or the joining of two plates together in order to form the aperture through which an anchor would extend through. Accordingly, constructing a collar 10, as described herein, by stampings reduces the amount of material and time required to construct the collar 10, saving costs. For example, each wing 64 of the collar 10 is a single layer of material whereas previous stamped collars required wings of two or more layers of material.

Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. For example, where specific dimensions are given, it will be understood that they are exemplary only and other dimensions are possible.

When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above products without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

1. A wall anchor for use in a cavity wall that connects to a veneer tie to join an inner wythe and an outer wythe of the cavity wall, the wall anchor comprising: an elongate body having a driven end and a driving end, the elongate body defining a longitudinal axis extending from the driven end to the driving end, the driven end being configured to connect to the inner wythe of the cavity wall; and a collar configured to connect to the veneer tie, the collar including a body mounting portion mounted on the elongate body adjacent to the driving end and defining an aperture through which the elongate body extends, the body mounting portion including a first aperture forming portion and a second aperture forming portion, the first and second aperture forming portions defining at least a portion of the aperture through which the elongate body extends, the first and second aperture forming portions being longitudinally offset with respect to one another along the longitudinal axis of the elongate body, the first aperture forming portion being formed as a single layer of metal having an internal surface facing toward the longitudinal axis, the collar including a first void radially opposite the internal surface of the first aperture forming portion, the second aperture forming portion being formed as a single layer of metal having an internal surface facing toward the longitudinal axis, the collar including a second void opposite the internal surface of the second aperture forming portion.
 2. The wall anchor of claim 1, wherein the first and second aperture forming portions are disposed on opposite sides of the longitudinal axis.
 3. The wall anchor of claim 1, wherein the first and second aperture forming portions are longitudinally spaced apart from one another along the longitudinal axis such that the first and second aperture forming portions define a longitudinal gap there-between.
 4. The wall anchor of claim 1, wherein the body mounting portion further comprises a third aperture forming portion defining at least a portion of the aperture through which the elongate body extends, the third aperture forming portion being longitudinally offset with respect to at least one of the first and second aperture forming portions along the longitudinal axis.
 5. The wall anchor of claim 4, wherein the third aperture forming portion is longitudinally offset with respect to both the first and second aperture forming portions.
 6. The wall anchor of claim 5, wherein the first and second aperture forming portions are longitudinally spaced apart from one another along the longitudinal axis such that the first and second aperture forming portions define a first longitudinal gap there-between and wherein the second and third aperture forming portions are longitudinally spaced apart from one another along the longitudinal axis such that the second and third aperture forming portions define a second longitudinal gap there-between.
 7. The wall anchor of claim 5, wherein the first and second aperture forming portions are disposed on opposite sides of the longitudinal axis and wherein the first and third aperture forming portions are disposed on the same side of the longitudinal axis.
 8. The wall anchor of claim 1, wherein the collar and elongate body are free to rotate with respect to each other about the longitudinal axis.
 9. The wall anchor of claim 1, wherein the collar further comprises first and second wings connected to the body mounting portion, each wing extending from the body mounting portion in a direction that is away from the longitudinal axis.
 10. The wall anchor of claim 9, wherein each wing defines a connecting aperture configured to receive a portion of a veneer tie to connect the veneer tie to the collar.
 11. The wall anchor of claim 1, wherein the collar is formed as a single piece of material.
 12. The wall anchor of claim 11, wherein the aperture forming portions are deformations of the single piece of material.
 13. A collar that connects a veneer tie to an elongate body of a wall anchor to join an inner wythe and an outer wythe of the cavity wall, the collar comprising: a body mounting portion configured to be mounted onto the elongate body adjacent an end of the elongate body, the body mounting portion defining an aperture configured to receive the elongate body, the aperture defining a central axis that extends through the aperture, the body mounting portion including a first aperture forming portion and a second aperture forming portion, the first and second aperture forming portions defining at least a portion of the aperture configured to receive the elongate body, the first and second aperture forming portions being longitudinally offset with respect to one another along the central axis of the aperture, the first aperture forming portion being formed as a single layer of metal having an internal surface facing toward the longitudinal axis, the collar including a first void radially opposite the internal surface of the first aperture forming portion, the second aperture forming portion being formed as a single layer of metal having an internal surface facing toward the longitudinal axis, the collar including a second void opposite the internal surface of the second aperture forming portion; and at least one wing connected to the body mounting portion and configured to connect to the veneer tie, the at least one wing being formed by a single layer of metal.
 14. The collar of claim 13, wherein the first and second aperture forming portions are disposed on opposite sides of the central axis.
 15. The collar of claim 14, wherein the body mounting portion further comprises a third aperture forming portion defining at least a portion of the aperture through which the elongate body extends, the third aperture forming portion being longitudinally offset with respect to both of the first and second aperture forming portions along the central axis, the third aperture forming portion being on the same side of the central axis as the first aperture forming portion.
 16. The collar of claim 15, wherein the collar is formed form a single piece of sheet metal and the first, second and third aperture forming portions are deformations of the sheet metal.
 17. A method of making a collar that connects a veneer tie to an elongate body of a wall anchor, the method comprising: cutting a collar blank from a sheet of metal; deforming outwardly in a first direction from a remainder of the collar blank a first aperture forming portion; deforming outwardly in a second direction opposite the first direction from the reminder of the collar blank a second aperture forming portion at a location on the collar blank so that as deformed from the collar blank the first and second aperture forming portions are aligned to define an aperture having a central axis, the first and second aperture forming portions being offset from each other along the central axis and the aperture being sized and shaped to receive the elongate body therethrough along the central axis for mounting the collar on the elongate body, the first and second aperture forming portions each being formed by a single layer of the sheet of metal; forming a structure on the collar blank configured to connect the veneer tie to the collar, the structure including a single layer of the sheet of metal.
 18. The method of claim 17, further comprising deforming in the first direction from the remainder of the collar blank a third aperture forming portion at a location on the collar blank so that as deformed from the collar blank the first, second and third aperture forming portions are aligned to define the aperture, the first, second and third aperture forming portions being offset from each other along the central axis of the aperture.
 19. The method of claim 18, wherein forming structure on the collar blank to connect to the veneer tie to the collar comprises punching an opening in the blank at a location spaced radially from the first, second and third aperture forming portions.
 20. The method of claim 18, wherein the steps of deforming the collar blank to form the first, second and third aperture forming portions occur simultaneously. 